Grafted textile product and method for grafting the product

ABSTRACT

An applique such as a lace-trimming is grafted onto a region of a textile product, such as a towel or a pair of blue-jeans. Previously, said region is marked by lockstitching on the product base material by means of an embroidering machine and removed therefrom, preferably by cutting or punching in a press. The applique is then bridged onto the removed portion of the base material with only a small overlap thereover and joined thereto by embroidering a seam all the way round the overlap with the machine. The seam is preferably about 4 mm wide and the overlap between 2 mm and 3 mm. A method is disclosed wherein the product is permanently retained in a hoop between the marking and joining steps, through the removing step, thus enabling the product to be uniquely placed relative to the embroidering machine before and after temporary removal to the press.

BACKGROUND OF THE INVENTION

The instant invention concerns textile products made from material suchas cloth, leather and plastics. The present invention may be applied toall kinds of fabrics or non-woven products such as towels, clothes andlinen in particular, although it is by no means limited to suchproducts. More particularly, the invention refers to base productsexhibiting appliques of like or different material grafted on apreselected spot or region thereof, generally for reasons of ornamentaldesign or marketing needs.

The present invention is disclosed hereinafter with reference to a towelwhich is grafted with an applique of lace trimming to make it moreattractive or give it a more distinguished appearance, notwithstandingthat the scope thereof spans a broader range of products such as shirts,trousers and table-cloths, for instance. It should be apparent to thoseskilled in the art how to adapt the present invention from the ensuingdisclosure to other applications, such as grafting a lace trimming onthe back pocket or legs of a pair of blue-jeans.

SUMMARY OF THE PRIOR ART

When it was desired heretofore to apply an ornamental applique on someregion of a towel, said region was simply put into a frame, the appliquewas temporarily affixed to said region by means of a preglued substrateand an embroidering machine was used thereafter to embroider or sew aseam all around the edge of the applique. Automatic pre-programmedembroidery machines were used for this step wherein the shape of theseam or embroidery was previously designed and stored in a memory chip,generally from a diskette, tape, carton or hard disk recorded on acomputer using a computer-aided design (CAD) system or by hand. Atechnique for this is disclosed, for example, in a manual named "How ToEmbroider" by Tajima Corp. of Japan.

The above-referred technique results in a visually attractive productalthough it has some drawbacks, which the present invention aims toimprove or overcome, as a result of that the base material of theproduct and the grafted material of the applique are superposed in theregion of the applique of the finished product. That is, two distinctcloth materials superpose one another, such that the product is felt tobe thicker in the referred region, which may be uncomfortable to a useror cause a distasteful impression to a potential buyer. Furthermore,both materials may be subjected to unequal stresses which wrinkle thisregion or hinder ironing the product. Moreover, when the product iswashed, the time the grafted region takes to dry is longer, as happenswith clothes having an elastic band at the waist, cuffs, etc.

SUMMARY OF THE INVENTION

An object of the present invention is to differentiate and substantiallyeliminate the superposition of materials in the region of the appliqueor graft, to overcome the difficulties outlined above and obtain in turna look-like one-piece woven product having optimum finishing touches andaesthetic appearance.

Another object of the invention is to suggest a relatively simple methodfor applying the applique, insofar that it comprises a series of extrasteps, relative to the method used heretofore, which are relatively easyto carry out for one skilled in the art.

An additional object of the invention is a method for applying the graftwhich may be implemented by means of a conventionally programmedautomatic one-head or multihead embroidering machine, without muchdifficulty.

Yet another object of the invention is to suggest a method for carryingout the graft which during the different steps thereof maintains aprecise registration or alignment between a portion punched or cut outin the material of the product and the graft material, in particularduring the step wherein the product is removed from the machine forcutting and removing the portion of base material where the graft is tobe applied, so that the joint formed thereafter between the applique andthe rest of the product may be effected with millimetric precision, suchthat there is excess or insufficient material at no point around theedges of the graft that would produce a defective seam or ruin thegrafted product.

The above and other objects and advantages that may become apparent fromthe ensuing disclosure are achieved by starting out with a product, suchas a towel, and cutting out a portion of the material thereof in apreselected region to be grafted, preferably having the same shape asthe graft or applique. This is done by fitting the product in a hoop orequivalent shuttle frame means big enough to contain the region of thegraft and stressing the region taut enough so that it is firm andwithout play. Thereafter, the preprogrammed shape is marked on theproduct, inside said region, preferably by lock-stitching with theembroidering machine once the hoop, with the product, has been fitted ina unique position in the machine. The hoop is then removed from themachine together with the marked product for removing the portionsurrounded by the marked out shape, such as by means of a pressinstalled with a hollow die cut, preferably of the same shape andslightly smaller size relative to the applique to be grafted. Theremoved portion is discarded and the hoop, still with the product, isput back into the machine in the same unique position as before.

Terminal steps similar to the prior art-may then carried out to graftthe applique in place of the hole left by the removed portion. However,according to another aspect of the invention, the step of grafting orjoining the applique to the product includes forming a provisionalbridge between the applique and the base product, to keep the appliquemated exactly on the hole while embroidering the seam joining theapplique to the product. The bridge may comprise a piece of paper orother throw-away substrate which is tacky on the inside so that itsticks to the applique and a surrounding part of the base product duringthe embroidering step and which, thereafter, may be easily peeled off.Alternatively, the bridge may be placed only while a baste is tackedaccross the applique over the hole and extending beyond both edges ofthe applique, the bridge being peeled off thereafter such that the basteforestalls relative movement between the applique and the base productduring the rest of the joining step.

The joint and finishing of the end product are optimum in view of thatthe overlap resulting from the invention between the applique and theproduct is minimum and narrower than the seam, hardly noticeable to aperson. One of the main features of the invention is that the product isnot once removed or otherwise loosened from the hoop between the markingstep and the joining step, not even when the product is temporarilyremoved from the embroidering machine and transferred to and from thepress and the discarded portion removed, thus resulting in that thefinal seam or embroidery is inherently placed and sewn around the graftin exactly the same place as the initial lock-stitching which marks thecut-out shape, both of which follow a unique pattern previouslyprogrammed into the embroidering machine.

The method of the instant invention may be carried out on an industrialscale by using embroidery machines installed with one or more spindleheads. The machine and press steps may be intertwined with differentproducts to reduce idle time without loss of placement precision.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-stated and other novel features and aspects of this inventionand how it may be reduced to practice may be understood better from thefollowing detailed description of a preferred embodiment shown in theattached drawings, wherein,

FIG. 1 is a drawing of a towel wherein the novel steps of the inventionare schematically set out.

FIG. 2 is a schematic in perspective of a spindle-head and the workingregion associated therewith of an embroidering machine, also showing ahoop for the product in a dismantled is state.

FIGS. 3A to 3E illustrate different steps of the method, FIG. 3E showingthe finished product with the graft.

FIG. 3F illustrates an alternative step to 3D wherein a bridge isremoved after a basting operation and before the final grafting seam iscompleted.

FIG. 4 shows an embodiment of a die cut suitable for the cutting-outstep of the method of the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring first to FIG. 1, a towel 11 is shown there comprising a blankbase material or starting product 13 of towel cloth to which it isdesired to graft an applique of lace trimming 15 in a preselected region17, for example centered near a hem 19 of the towel 11. In the presentembodiment, the starting product may be a towel, however other knit,woven or non-woven materials may be used. The lace trimming applique 15is of a predetermined geometrical FIG. 21 and, according to theinvention, is grafted onto the product 13 to become, at least visuallyspeaking, an integral part of the towel 11.

In order to achieve this, following the steps of the method discribed inmore detail hereinafter, the towel base product 13 is previously cutalong a figure or shape 23 determined by the perimeter 21 of the lacetrimming 15 and the material 27 cut out is thrown away as indicated bythe arrows 25. The lace trimming is then centered exactly over or underthe hole 29 left in the product 13 and joined thereto by a seam runningaround the slightly overlapping edges 21-23. In accordance with theinvention, the amount of overlap between edge 21 of the lace trimming 15and the edge 23 of the portion removed from the product 13 along thejoint or seam is only about two or three millimeters accross, so thatapplying a conventional attractive embroidery four millimeters wide, forexample, fully integrates the graft or applique 15 into the towelproduct 11 and provides a finishing touch with no visual defects. Thesemeasurements are generally on the minimum since wider overlaps may beembodied if desired.

FIG. 2 illustrates a part of an automatic programmed multiheadembroidering machine 31, suitable for this job, such as model TMEF-H612manufactured by Tokei Industrial Sewing Machine Co., Ltd. of Japan. Themachine 31 is installed with twelve spindle-heads 35 electronicallycontrolled by a programmed Tajima controller 33, although other meanssuch as a Toyota Expert 820 system may be used alternatively. FIG. 2only shows one of the twelve like heads 35 of the machine 31. Eachspindle-head 35 is installed with six (or sometimes twelve) needles 37,each associated with a different spool of thread (not illustrated) forautomatically embroidering with threads of different colours.

The twelve spindle-heads 35 are installed with the, say, six needles 37of each directed to a general work region within a moving master frame39 supported on a machine table 41. The frame 39 is moved over the flattable 41 by two actuators 43X and 43Y, which generate perpendiculartranslation directions from control signals received from the electroniccontroller 33. This controller 33 includes storage means, such as aprogrammable memory chip (not illustrated), for holding codes defining apath around the edges 21-23 in storage together with other programinstructions for carrying out the initial lock-stitching and thefinishing embroidery, as described hereinafter.

The product 11 is firmly and uniquely placed in the embroidering machine31 by means of a removable shuttle frame or hoop 45 which may beuniquely set by means of an adapter 55 in the frame 39 the adapter andframe may be made as an integral piece if desired. This hoop 45comprises an outer hoop part 47 and an inner hoop part 49 dimensioned tofirmly hold the cloth of the product 11 so that the work region 17 isentirely within the circumference of the hoop 45. The outer hoop 47 is apart made of plastics, generally having a square cross-section,furnished with screw means 51 for finely adjusting the circumferencethereof. The inner hoop 49 is made from a round metal bar bent nearlyinto a full circumference open between two ends 53 perpendicular to theplane of the circumference of the hoop 49. These ends 53 may be fingerpressed towards each other to make the inner hoop 49 temporarily smallerso as to be able to force it over the product 13 and press it downinside the outer hoop 47 such that the product 13 is retained inbetween. Alternatively, a rigid closed hoop could be used for the innerhoop part which is pressed into the outer hoop part 47.

Each hoop 45 is removably set in the frame 39 by means of the individualadapter 55 fixed to the frame. The adapter 55 may be a generallyrectangular flat piece of wood, plastics or other suitable material. Thetop face of the adapter 55 may be carved or moulded into the shape ofthe hoop 45. In the present embodiment, the outer hoop part 47 protrudesradially outwards where the adjustment screw 51 is, so that it may fitin the adapter in only one way, thus enabling the hoop 45 to be uniquelyset in the adapter 55 and, therefore, relative to the spindle-headarrangement 35.

FIGS. 3A to 3E portray a sequence of method steps for carrying out theoperation depicted in FIG. 1 with the machine of FIG. 2. In FIG. 3A, thebase product 13 of the towel 11 is placed relatively taut inside thehoop 45 which is then assembled into the frame 39 of the embroideringmachine 31. In FIG. 3B, the top face of the towel material 13 of theproduct 11 is marked with the FIG. 23 by means of a lock-stitchingoperation performed by the needles 37 of the spindle-head 35, accordingto a design previously stored in a chip read by the controller 33.

The hoop 45 is removed from the machine 31 together with the just markedproduct 13 and transferred to a press (not illustrated) where thelock-stitched mark 23 is visually aligned with a hollow die cut 57. Oncethe product 13 has been perforated by the die cut 57 as depicted in FIG.3C, the hoop 45 is removed again from the press and reinstalled in theframe adapter 55 of the machine 31.

FIG. 4 illustres a die cut 57 by way of example, manufactured from asteel strip 59 bent into the shape of the figure or design 23. In thisexample, the FIG. 23 is a simple oval shape, which is pretty attractivein the case of grafted towels 11, however any other desirable figure,such as in the shape of a heart, may be designed within the scope of thepresent invention. The bottom edge 61 of the strip 59 is sharpened toform a cutting edge and a cross strip 63 may optionally be welded inplace inside the oval strip 59 to avoid the shape of the latter frombecoming deformed with use and also to serve as a handle forfacilitating installing and removing the hoop 45 from the press and theembroidering machine 31.

The invention is based on that the adapter 55 is static within the frame39 of the machine 31 and that the hoop 45 fits exactly in the adapter 55in only one way, as described hereinabove. Hence the hoop 45 holding theproduct 13 may be uniquely situated relative to the embroidery machine31, making it inherently possible, by keeping the base product 13permanently inside the hoop 45 and sufficiently taut to avoid anyrelative shift therein, to return the base product 13 to theembroidering machine 31 in exactly the same position it had relative tothe spindle-head for the initial lock-stitching marking operation.

As set forth in FIG. 3D, the hole 29 punched out by the press is coveredby the applique 15 to be incorporated, using a bridge 67 such as a sheetof paper or discardible material which is pasted with glue substance tohold the applique 15 in place over (or under) the hole 29 such that theedges 21 and 23 uniformly overlap preferably less than eightmillimeters, more preferably just about two to four millimeters, all theway round. The spindle-head 35 is turned on again in this position toembroider a seam 65 all the way round the edges 21-23. The glue-paperbridge 67 allows the seam to be embroidered by the machine 31 withoutthe applique shifting relative to the base material 13. The glue-paper67 is removed thereafter leaving the towel 11 with the applique 15definitively integrated thereinto, as may be seen from FIG. 3E.

Alternatively, the bridge-paper 67 may be removed after tacking a baste69 accross the applique 15 and base product 13, as shown in FIG. 3F, tohold the applique 15 in place over or under the hole 29 while thegrafting seam 65 is embroidered.

In carrying out the invention on an industrial scale, the manufacturingsteps may be entwined to avoid the machine 31 idling while the productis away at the press. That is, while the marked product 13 is undergoingthe punching step shown in FIG. 3C, another product may be at themachine 31 undergoing the marking or joining step, extra hoops 45 beingprovided to this effect.

Of course, changes, variations and aggregations may be applied to theabove-detailed embodiment, without departing from the scope nor thespirit of the invention. The same has been described by way of apreferred embodiment specifically for a towel product 11, however thoseskilled in the art may suit it to other applications or introducemodifications without departing from the purview of the invention as setforth in the appended claims. For example, the die cut 57 and theassociated press may be replaced by cutting means incorporated into thestructure of the machine 31 and functionally operated from thecontroller 33 under a preprogrammed sequence of instructions.

I claim:
 1. A method for grafting an applique in a pre-selected regionof a product, said applique having a preselected shape and size, saidmethod comprising the steps of:fitting said product into a hoop in a waythat said region is entirely inside said hoop, removing a portion ofmaterial from said region of the product, whereby a hole is formed insaid product having a same shape and slightly smaller size relative tosaid applique; covering said hole with said applique such that saidapplique overlaps a strip of product material all the way round saidhole; joining said applique to the strip of overlapping material of saidproduct; and wherein said steps of removing, covering and joining arecarried out sequentially without removing or substantially looseningsaid product from said hoop.
 2. A product grafted by the method of claim1 comprising:a base material; and at least one region having an appliquegrafted therein, the perimeter of said applique forming a geometricfigure of a preselected shape; wherein a portion of said base materialis removed from said region, said removed portion defining an edgesubstantially having the same shape as said figure, and said applique isgrafted onto said base material substantially in place of said removedportion and is joined to said base material substantially around saidapplique perimeter, wherein said edge of the portion removed from saidbase material and said applique perimeter overlap substantiallyuniformly all the way round and said applique is joined to said basematerial by a seam, the width of said seam being greater than theoverlap between said applique and said base material.
 3. The product ofclaim 2, wherein said seam is not more than 8 mm wide.
 4. The product ofclaim 3, wherein said seam is not more than 4 mm wide and said overlapis less than 3 mm.
 5. The product of claim 1, wherein said product is atowel.
 6. The product of claim 5, wherein said product is a product ofclothing or linen.
 7. The product of claim 4, wherein said applique islace trimming.
 8. The product of claim 4, wherein said base material issubstantially blank and said applique includes a design.
 9. The methodof claim 1, further including the step of marking a figure on saidproduct substantially similar to said preselected figure, in betweensaid fitting and said removing steps and wherein said steps of marking,removing, covering and joining are carried out sequentially withoutremoving or substantially loosening said product from said hoop.
 10. Themethod of claim 9, wherein said marking step and said joining step arecarried out on an embroidering machine including frame means andstitching means, and said hoop in which the product is fitted is aremovable hoop fitting into said frame; said marking stepcomprises:fitting said removable hoop in a unique position into saidframe and operating said embroidering machine to lock-stitch said figureon said product material.
 11. The method of claim 10, wherein saidremoving step comprises:removing said removable hoop from said frame;punching out said said portion from said product material; and fittingsaid removable hoop into said frame back into said unique position. 12.The method of claim 11, wherein said punching step is carried out in apress including a die cut having a cutting edge of substantially thesame shape and slightly smaller size than said applique, said punchingstep comprising:registering said figure marked out in said region withsaid cutting edge; and operating said press to cause said die cut topunch out said portion.
 13. The method of claim 10, further includingusing said embroidery machine, while said product is undergoing saidremoving step at said press, for carrying out said marking or saidjoining step on another similar product.
 14. The method of claim 13,wherein said joining step comprises grafting said applique onto saidproduct by embroidering a seam all the way around said applique.
 15. Themethod of claim 13, wherein said seam is embroidered to coversubstantially all said strip of overlapping material.
 16. The method ofclaim 14, wherein said covering step includes, prior to embroideringsaid seam:providing a bridge having a surface larger than said appliquepasted with an adhesive substance; removably adhering said applique tosaid surface such that a portion of said surface pasted with saidadhesive substance is free; placing said bridge across said hole suchthat said pasted portion contacts said product; and keeping saidapplique in place while said seam is embroidered.
 17. A method forgrafting an applique in a preselected region of a product, said appliquehaving a preselected shape and size, said method comprising the stepsof:removing a portion of material from said region of the product,whereby a hole is formed in said product having a same shape andslightly smaller size relative to said applique; covering said hole withsaid applique such that said applique overlaps a strip of productmaterial all the way round said hole; placing and removably adhering abridge across said applique such that parts of said bridge extend beyondsaid applique and contact parts of said product, said bridge having asurface facing said applique pasted with an adhesive substance such thatsaid applique is temporarily affixed to said product over or under saidhole; and grafting said applique onto said product by embroidering aseam all the way around said applique, and said bridge is removed aftercompletely embroidering said seam.
 18. The method of claim 16, whereinsaid bridge is removed after completely embroidering said seam.
 19. Themethod of claim 17, wherein, in between said placing and said graftingsteps, a baste is tacked accross the applique beyond two edges thereof,whereafter said bridge is peeled off said applique and said productbefore said seam is embroidered.
 20. The method of claim 17, whereinsaid bridge comprises a sheet of paper or cardboard material.